5S – an inseparable improvement tool for manufacturing processes

With the aim of creating and maintaining a convenient, fast, accurate and efficient working environment at every work location of the office area, production site, warehouse, materials or locations around the yard, parking space … 5S is a useful tools are inseparable from the production process.

Within the framework of the Ministry of Industry and Trade’s 5S Good Practice Guidance for EPRO Consulting Joint Stock Company to implement, Viet Thang Garment Joint Stock Company has implemented 5S implementation in 3 different areas including: Warehouse accessories of sewing factory 3, cutting a section of garment factory 1 and professional department of the company office area. At the same time, established 5S Steering Committee with 5 members and divided management to help companies in the company more proactive and responsible in implementing 5S.

Mr. Nguyen Duc Doanh – Head of Human Resources Department – May Viet Thang – said that after implementing the 5S rule, the company has improved the production environment, classified materials to see signs and will be arranged tidy and neat. The entire wire under the desk in the office area is neatly compacted, easy to clean, etc.

Thanks to that, it has reduced the area of the area at the cutting area, auxiliary warehouse, saving time and production costs, employees’ sense of compliance increased significantly. From an initial standard assembly line, now, 5S has been widely deployed by May Viet Thang throughout the company.

Also, according to Mr. Nguyen Duc Doanh, during the process of implementing 5S, the company invested VND 38,492,000 for items to buy additional tables, chairs, filing cabinets, tool cabinets, 5S labels and salary allowances for employees ministry participated in 5S study. Additional check sheet to keep track of codes cut, cut date to make it easier to manage and liquidate when the item code has expired.

Particularly, the company has assigned leaders to assess 5S every day to maintain internal and remind employees in their management areas to strictly comply with 5S regulations. The implementation of 5S has helped employees reduce the time to search for documents and papers in use; reduce time, cut and stay under the cutting table; cut using are also easy to search. The program helps May Viet Thang to train and guide 5S good practices for more than 50 officials and employees.

Meanwhile, Son Ha Energy Development Joint Stock Company (SHE) is a famous manufacturer of solar water heaters in the market. With the desire to improve production efficiency, the Company has registered to participate in the program “Training and guiding the implementation of 5S good practices at enterprises in the industry and trade” jointly coordinated by the Ministry of Industry and Trade and EPRO Consulting Joint Stock Company integrated implementation.

5S good practice is implemented by SHE on the whole factory in Phung Industrial Park, Dan Phuong District, Hanoi City under the direction of Mr. Hoang Manh Tan, Director of the company and under the management of Mr. Dang Van Thuy – Factory Manager, etc.

After 6 months of implementation, SHE has obtained some results as follows: The working environment of the whole factory becomes clearer, cleaner and safer, the spirit of employees is better. At the material warehouse, reduce the time of import and export, reduce inventory time from 3 days to 1 day (only 01 staff performs).

In the packaging area, the components are better managed, reducing spillage and confusion during packaging. In the finishing area, workers operate more conveniently and make the overall productivity increase by 16%. Workers are better aware of 5S, so the implementation of 5S has become more intrinsic and not as anti-institutional as before.

Compared to the initial goal of registering for the program, this result is in line with business expectations and consulting, the productivity of the factory is also significantly improved. Mr. Nguyen Ngoc Thanh, Deputy Head of the Insulation Team and Member of the 5S Board emphasized: “Thanks to 5S, the transfer of semi-finished products between stages, especially in the insulation zone has been much faster and more productive. The increase of the nest is obvious, in addition, the team also cut a manpower to maneuver to another department ”.

Good implementation of 5S not only improves labor efficiency, but also changes the attitude of the workers. Ms. Nguyen Thuy Duong, a warehouse staff member shared: “It was difficult to get anything in the past, especially stamps and water pipes. Now that everything has a subdivision, a clear address, so my job is much more convenient, the inventory time is concentrated, only one I do during in the day is done. ”

Or at Viet Pan Pacific Co., Ltd. (Bac Giang City) over the past 2 years, successfully applied 5S management model in the production process.

The face of the Company has changed significantly. It is known that the unit has applied the ISO 9001: 2008 system to the production line. However, ISO does not require a working environment while the characteristics of dusty garment industry and metal items are easy to cause pollution and labor accidents. Overcoming this limitation, the unit has applied 5S tool. Ms. Le Thi Hanh, Chairman of the Trade Union and the Manager of the company said: “5S helps the leadership team to the workers, the employees all have the self-cleaning style, neatly working place. Workers often stow metal tools into a box; hygiene of work areas and equipment; seriously wear a mask. The air of the workshop is cleaner. The rate of workers infected and occupational accidents decreased, machinery was less damaged ”.

According to Mr. Nguyen Phuc Thuong, in the coming time, units need to focus on propaganda to raise awareness for officials and employees to understand 5S benefits; at the same time invest in upgrading infrastructure; regularly check and evaluate 5S performance results; promptly remedy inappropriate factors.

On the functional agencies, the Department will prioritize funding for typical enterprises; at the same time, strengthening the information of support policies for the units to access preferential capital when applying 5S; strive for 2020, about 30% of enterprises in the province successfully applied 5S.

Productivity and Quality Office

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